A generous fillet was added around the BOV mount and here is the final part:



I ordered a prototype printed in PLA and it was less than $100 shipped. The aluminum part should come in under $600.

Andrew

 

We are living in marvelous times.











If I can only find the BOV in a box somewhere so I can confirm fitment....::facepalm::

Andrew

 

That's pretty amazing! You're definitely doing some next level modifications on this thing.

 

That is so freakin cool!
What about all that white stuff you sprayed everywhere, easy to clean up I hope?

 

Thanks guys! I have not tried cleaning off the foot powder, but it seems to wipe right off. I am not concerned about it.

The reason that I have not cleaned it up yet is because I need to scan the top of the intake fully so that I can have something designed that will hold the shaker scoop to the top of the engine.

Andrew

 

Is the shaker going to be functional, feeding the turbo inlet?

 

I don't see any clean way that it can be functional.

Andrew

 

BOV fitment confirmed:






Andrew

 

Here is the updates design. The BOV location was moved, the logo was moved, and there wall thickness on the little nipple by the compressor exit was increased (not visible).























Andrew

 

What was the reason for relocating the BOV?
did you use CFD to determine the second location was better? Seems like you don’t really do anything in a haphazard way. So, there must have been a compelling reason.

 

Also, how is the elbow being made? 3D printed in aluminum, cast, or CNC machined?

 

I asked the opinion of a few people that I trust, who have experience with this kind of stuff, and the design was revised based on their feedback. I also decided I wanted the BOV more hidden. This design is a result of both function and aesthetics.

It will be 3D printed out of aluminum. I have a final prototype coming and this one is being made printed out of carbon reinforced PET. I chose that for no other reason other than I wanted to see a difference between it and PLA.

Andrew

 

Here is the second prototype printed in carbon reinforced PETG.



















I like the new BOV placement and the slightly repositioned logo.

The next step is to have the final version printed in aluminum.

Andrew

 

That is so freaking cool Andrew.
Just showed this to my 14-year-old son who's big into 3D printing, he's asking who did the printing for you if you don't mind me asking?
Why not just run the one made?
My son seems to think it'd be plenty strong for what you're doing and shed heat better than aluminum.

 

I used a broker called CraftCloud.

I seriously doubt that the CF PETG would hold up to boost and heat. Keep in mind that the air coming out of the turbo is going to be about 250 degrees F at 20psi, plus all of the ambient heat in the engine bay. I just ordered the aluminum part.

Andrew

 

PETG would almost certainly fail under those temps and pressure, but PC or nylon would probably hold up fine, and weigh less than aluminum. That being said, I would 100% go with aluminum given the option. I would love to see fluid flow models, but your revised BOV location almost has to be less disruptive to airflow than the original location.
edit-- I have seen quite a few strength tests on CF infused filaments, and they are not much if any stronger with CF than without. They mostly seem to just look cooler.

 

I am sure that there are various composite materials that will handle the heat and pressure if they were properly designed. The wall thickness of this particular intake is 0.125" so it was always designed with the understanding of being printed in aluminum. The aluminum printing will also show the details of the logo a lot better because each aluminum layer is only 0.05mm as opposed to the 0.2mm layers for the PETG. There are other considerations, like the BOV mount and the o-ring clamp at the compressor discharge. Those dimensions are quite delicate and can't really be changed to accommodate thicker wall thickness. In fact, when I was messing around during mock up, a thin portion of the BOV mount developed a small crack.

If weight was an absolute concern, various methods could be used make this part out of pre-preg carbon fiber, but that would end up costing more than the 3D printed aluminum part.

Andrew

 

Dumb question, how do you deal with expansion?

I'd have to imagine the turbo manifold will grow/shift/move with heat. Probably not much, but it's gotta, right?

Or maybe I have no clue how that stuff works. Either way, it's really cool.

 

Actually that is a great question. At the throttle body it will be attached with a silicone coupler, which allows for movement. There is about a 1/8" gap between the compressor outlet and the tube, and that is to accommodate dimensional changes due to heat. Those o-ring clamps can also accommodate quite a bit of angular misalignment.

Andrew

 

Andrew, this is really looking cool. Thanks for sharing all the intricacies of this build with us.

Did you know Nick Williams makes a DBW throttle body with a dual seal connector as well? While a silicone coupler will work, and certainly be cheaper, the cool factor might increase… if that’s even possible! lol